WO2019068968A1

WO2019068968A1 - Multilayer connector insulated by impregation with resin

Info

Publication number: WO2019068968A1
Application number: PCT/FR2018/000230
Authority: WO
Inventors: Daniel ROGER; Jean-François WECXSTEEN; Stéphane DUCHESNE; Gabriel VELU
Original assignee: Auxel; Universite D'artois
Priority date: 2017-10-06
Filing date: 2018-10-04
Publication date: 2019-04-11
Also published as: CN111183578B; FR3072217A1; FR3072217B1; EP3692625A1; CN111183578A; EP3692625B1

Abstract

The subject of the invention is a method for manufacturing a multilayer connector device capable, inter alia, of forming inter- or intra-solid-state power converter connections (power module circuits, capacitors, filters, connectors, etc.), said device comprising at least two flat conductors and at least one insulating material arranged between the aforementioned two conductors, said method being characterized in that the optionally prepared flat conductors are positioned in a tank in a geometric position such that the conductors are held parallel and separated by a value that is at least equal to the desired thickness of the electrical insulation, said conductors having a preferential orientation; said prepared flat conductors are impregnated with at least one impregnating resin introduced into the tank, said impregnating resin having physico-chemical characteristics allowing it to be kept in the form of a layer coating all of the accessible faces of said prepared flat conductors; the device is taken out of said tank and said resin is crosslinked.

Description

INSULATED MULTILAYER CONNECTOR BY IMPREGNATION OF

RESIN

Technical field of the invention

The invention relates to the technical field of electrical installations, conductors and power distribution, and the field of devices and methods for the manufacture of such devices.

More particularly, the invention relates inter alia to a multilayer connector also called "busbar" laminated electrically insulated by resin impregnation and secondly the method of manufacturing said "busbar". Prior art

The term "rolled busbar" is usually understood to mean an electrical interconnection device, whose functions are to electrically connect the constituent elements of a static converter of electrical energy; but also to ensure the connection connection provided outside said converter.

This connection occurs in several contexts for example:

• between power modules such as: insulated gate bipolar transistors (IGBTs), integrated gate-switched thyristors (IGCTs), diodes, and passive components such as capacitors or filters; implemented within this static converter of electrical energy, especially in the typical power range from 50kW (kilowatt) to 8 MW (megawatt),

• when the multilayer connector is directly encapsulated inside the power modules: between semiconductor circuits, and / or between semiconductor circuits and external connections (terminals). connection), especially in the typical power range from 5 kW (kilowatt) to 200 kW (kW).

The laminated multilayer connector also has the function of mechanically supporting the various elements involved.

The laminated multilayer connectors generally consist of a complex of flat conductors and insulating material (s). Nevertheless, the term "busbar" can also be used to designate a single flat conductor.

Flat conductor means a conductor such that one of its dimensions (preferably its thickness) is much smaller than the others. Such a conductor may be flat or bent.

This stack of flat conductors of different electrical phases justifies the main purpose of the laminated connector with respect to conventional connection bars or electric cables; namely a weak inductance.

By way of example, a laminated connector may consist of an assembly of several conductive plates, each plate corresponding to an electrical phase. Lights in the plates allow the connection of the components arranged on one side with the other plates below. The components are most often mounted by screwing. There are also connection tabs for connection with the outside of the converter. Most often, the electrical insulation between the different conductive plates is made by electrical insulating films of polyethylene terephthalate (PET), ethylene polynaphthalate (PEN), polyimide (PI) type. . . Usually, the said insulating film (s) is either stacked (sandwiched between conductors, it is called "busbar" rolled stacked or "stacked"), or laminated on the flat conductor ("busbar Laminated laminate).

These technologies have several disadvantages presented below. In the case of the "stacked" or stacked "busbar", it is necessary to provide a device for geometrically holding its elements at least until it is mounted in the converter. This device is generally in the form of additional fasteners of electrical insulating material. In addition, the isolation distances in the air limit the operating voltage level of converters made from such multilayer connectors (about 1000 volts).

In the case of laminating, the sheets are usually heat-sealed, which requires for example the use of a heating press, a shaping tool and flexible pressure distribution membranes. Such a device consumes a lot of energy, which represents a major technical disadvantage. Indeed, only about 1% of the energy consumed serves to secure the flat conductors and the film (s), the rest of the energy being dissipated at the metal casing of the press and the tool .

Due to the thermal inertia of the system and the thermal barrier formed by the flexible membranes, the production time is also long (of the order of 1 to 2 hours) and therefore the low hourly productivity; while future needs in static converter are increasing (renewable energies, electric vehicles, smart-grid, ...)

Another technical problem encountered when laminating insulating films relates to the insulation quality of the device and more specifically the insulation quality of its edges (driver periphery, edges of the openings provided in the conductors, etc.). In fact, ideally, the laminated connectors with heat-sealed film are manufactured flat and are then folded if necessary. The folding Posterior poses multiple risks: cracking of the film, cracking of the surface coating (for example: nickel plating). In addition, when laying the film (s), care should be taken not to create an air pocket (cavity filled with air between the film and the driver) or interstices (poorly glued or peeled film) at the borders, because such defects generate the appearance of parasitic and highly detrimental phenomena such as partial discharge phenomena (all the more important as the dielectric field is high), which cause more or less long-term drilling of the film insulation, and consequently the appearance of short circuits. The design of multilayer connectors having a high partial discharge threshold is therefore highly desirable.

Moreover, the increasing need for speed in the circuits requires the implementation of adequate electronic components and increasingly efficient, for example based on silicon carbide or gallium nitride. These introduce severe constraints for multilayer connectors, such as:

• inductance values required even lower than those currently achieved,

An ability to withstand an operating voltage higher than the voltages currently encountered,

• an ability to withstand a switched current higher than the switched currents currently encountered,

• Ability to withstand an operating temperature higher than the temperatures currently attained.

Thus, in order to meet the constraints mentioned above, currently used film (s) increasingly efficient materials, for example PolyEtherEtherKetone films (PEEK) or Polyimide (PI), but are much more expensive. Also, the rise in temperature poses the problem of finding films and adhesives resistant to it. Also, the main technical advantage of these devices, namely: a low inductance (compared to traditional wiring), is a consequence of their flattened shape. Thus, obviously, the current technological evolution is based on the principle of downscaling: it is known to reach lower and lower inductance values by reducing the thickness of the conductors and films. insulation. This solution nevertheless has an obvious limit, since thinner films are also more fragile and delicate to handle and / or stick.

Moreover, knowing that a low inductance makes it possible to limit the overvoltages during switching of the current in the electronic switches and that a threshold of appearance of partial discharges of higher and higher is required, it is all the more obvious that the Improving the performance of multilayer connectors, by choosing high-performance materials that are easy to remove and inexpensive, is an important technical challenge for the industry. US2012 / 242442 is known a winding consisting of flat elements between which must be preserved a space for air circulation, each flat element being individually isolated by resin in powder form and then assembled by screws or bolts.

Also known are conductive elements coated with an insulating material and using an insulating sheet between the conductive elements which are assembled by bolts.

A device is known in which a tape conductor is glued to an intermediate insulating tape, the resulting bar is immersed in a resin bath according to the fluidization process, and the coated bar is placed in a press. Description of the invention

As previously demonstrated, there is a real need to provide a solution in response to the technical problem of improving the insulation of drivers constituent flat rolled connectors (including the edges) and the application of the selected insulation material, while maintaining a reasonable manufacturing cost and increasing productivity.

The invention described in the present application meets this need, by proposing an economically attractive solution and increased performance for connectors produced according to the prescribed method, which overcomes all or part of the use of films.

To do this, the invention relates first of all to a method of manufacturing a connector device capable inter alia of making an inter or intra connection static converter (s) of electrical energy (power modules circuits, capacitors , filters, connectors, etc.), said device comprising at least two flat conductors and at least one insulating material disposed between said two conductors, said method is characterized in that:

The optionally prepared flat conductors are positioned in a tank in a geometric position such that the conductors are kept parallel and spaced apart by a value at least equal to the thickness of the desired insulation, said conductors having a preferred orientation,

These said prepared flat conductors are impregnated with at least one impregnating resin introduced into the tank, the said impregnating resin having physicochemical characteristics enabling it to be maintained in the form of a coating layer on all the accessible faces. said flat conductors prepared after extraction of the latter from said tank,

• the device is extracted from said tank, and

The crosslinking of said impregnating resin is carried out.

Advantageously, the conductors are placed in a positioning device that does not generate spatial constraints at the external dimensions of said device before introduction of the resin. The term "positioning device that does not generate spatial constraints on the external dimensions of said device" means a positioning device which has no influence during the manufacture of the device and / or at the level of the device. finalized on the external dimensions of said device.

By way of non-limiting example, and contrary to the positioning device provided by the invention, a mold (for example: for casting or injection) generates spatial constraints on the external dimensions of a connector device designed to help from it.

Indeed, the particular external conformation connector device manufactured is complementary to that of the mold used. The mold constrains (retains) spatially (in space, in volume) the material cast or injected into it. According to the invention, the combination of the difference between the conductors and the specificities of the liquid resin which make it possible during the extraction to maintain the liquid resin in place without the need for a mold.

According to the invention, the preparation step advantageously comprises at least one step of laying down at least one saving. These savings are for example preferably selected from the group comprising: plugs (for example: heat-resistant elastic material, and / or sealed, and / or mechanically fixed, and / or non-adherent material), adhesives (for example : peelable adhesives). Savings can all be of the same nature or be variegated. They can be reusable or disposable. Nevertheless, the skilled person knows how to choose the nature of the savings, and their number according to the needs of the device to be manufactured. The savings are intended to protect the conductive surfaces on which the components are fixed, these surfaces not having to be covered with insulation. Also, the method comprises a step of disposing said prepared flat conductors in an initial geometric position in said positioning device.

Preferably, said initial geometric position corresponds to a manufacturing position, and even more preferably to a remote position E _x if the positioning device is operable. The initial position corresponds to the tight end position S if the positioning device is not actuable. Furthermore, according to the invention, the method comprises laying spacers of given thickness to maintain a spacing chosen between the conductors. More preferably, the assembly is carried out by the resin "through" the positioning device, that is to say that it is not possible to distinguish an input and / or an output defined for said device. positioning (unlike for example a mold, which comprises at least one inlet for the material to be molded).

According to the variant of the method chosen, the step of collecting the connector device may among other things require:

• to separate the positioning device (and therefore the frame, and / or any other element that constitutes it, when said positioning device has one), and / or

• to disconnect savings if they exist.

The invention also relates to any connector device that can be obtained by implementing the previously described method. Said connector device is inter alia capable of making an inter or intra converter connection (s) static (s) of electrical energy, that is to say, it is suitable and likely to be used in order to make a connection :

• Intra-converter, that is to say for example: o between at least two power modules (as defined above) belonging to the same converter, or o inside a power module, for example: between at least two semiconductor chips, or between a semi chip - conductor and external connection, or

• Inter-converters, that is to say for example between at least two converters.

Thus, the invention particularly relates to a connector device obtained via the proposed manufacturing method, said device being remarkable in that it comprises at least two flat conductors and at least one insulating material such as a resin acting as an insulator and / or assembly means.

As previously described, the multilayer connector devices generally consist of a complex of flat conductors and insulating material (s).

According to the invention, the flat conductors are preferably made of copper or aluminum. Advantageously (but not necessarily) the conductors are protected by a surface treatment, such as among others: tinning, nickel plating, silver plating. Preferably, the conductors have a thickness of between 1 and 4 millimeters. The method of manufacturing conductors (for example: punching, folding, injection, casting) does not matter, and the skilled person knows how to choose the most suitable method for the intended application.

Finally, the invention is employable for various purposes (laminated busbars of static converter of electrical energy, internal rolled busbars of semiconductor power modules, etc.), and the Applicant claims in particular the use of any proposed connector device. obtained through the implementation of presented process, as a connector inter or intra converter (s) static (s) of electrical energy.

Description of the drawings

The invention will be better understood from the following description (by way of non-limiting example) of the drawings illustrating the interconnection device and the associated manufacturing method, where:

FIG. 1 represents a device for positioning a connector device with the flat conductors associated with it in its initial manufacturing position and any intermediate position (s).

Figure 2 shows the same positioning device with the connector device in the final manufacturing position. A detail of the different layers of varnish or resins and conductors is shown. Figures 3 to 5 show different stages of the manufacturing cycle of the connector device placed in an impregnation tank.

Description of general embodiments of the invention

According to FIGS. 1 to 3, the method according to the invention allows the manufacture of a connector device 1. This device 1 (and its steps / manufacturing principle) presented in FIGS. 1 and 2, in its geometric positioning device 40, thus comprises at least two flat conductors 2 and at least one insulating material 30.

Preferably, said device 1 is in multi-layer form, that is to say that it is possible to distinguish the set of various layers of materials that constitute it.

Advantageously, the insulating material 30 is one of: resin (s) 31, spacer (s) 32. When the insulating material 30 is a spacer 32, it is preferably in contact at least partially with the conductors 2. Nevertheless, in complex variants of the device, it is for example possible to combine the positions of the resins and the spacers; for example, the spacer can be placed between conductors 2 coated with enameling resin, so as to ensure a predefined spacing which will subsequently be filled by at least one impregnating resin.

The term "spacer" 32 an element separating at least two consecutive conductors 2. Optionally, several spacers (32) may also be in contact with each other when the arrangement of the device 1 requires it. Advantageously, said spacer 32 consists of at least one material that is not or only slightly compressible. Preferably, said spacer 32 is made of at least one electrical insulating material 30. In a most preferred manner, the outer surface of said spacer 32 is made of an insulating material 30.

Said spacer 32 may be full. Nevertheless, in preferred embodiments of the invention, said spacer 32 is porous. In advanced variants of the invention, the device 1 comprises at the same time: spacer (s) full 33, spacer (s) porous 34. The skilled person knows how to choose the most appropriate characteristics for the spacer 32, according to the specific needs of the intended application. Advantageously, when the spacer 32 is full, said spacer 32 is a film of insulating material. Preferably, said spacer 32 is a rigid film, for example a mica film 33.

Preferably, in the variants where said spacer 32 is porous, it is for example a felt block 34. The porosity allows the retention of (the) resin (s) by capillarity.

The assembly operations of the flat conductors 2 with insulators 32 also aim to geometrically stabilize the components together during the entire manufacturing cycle and to simplify the arrangement of the connector device 1 in the positioning device 40. When the insulating material 30 is a resin 31, the latter at least partially coats the conductor (s) 2. In some preferred embodiments of the invention, when the insulating material 30 is a resin 31, the latter coats completely the conductor (s) 2, that is to say that the conductor 2 is in contact exclusively with said resin 31.

Preferably, each conductor 2 is individually coated with at least one layer of enameling varnish 35 before assembly of the conductors 2.

Enameling varnish 35 is understood to mean a resin which has particular properties of adhesion to the electrical conductor 2, electrical resistance, thermal stability and adhesion with respect to other possible insulators, such as for example an impregnating resin.

Most preferably, the enameling varnish 35 comprises at least one filler in the form of inorganic particles of size preferably less than 150 μηι such as for example: silica (SiO2), alumina (A12O3), magnesia (MgO). Thanks to this inorganic filler, the resin has a lesser alteration of its electrical characteristics under partial discharge constraints.

The term "impregnating resin 36" refers to a resin in liquid form initially which has mechanical strength, chemical resistance, electrical resistance and, optionally, good retention by thixotropic effect. Most preferably, the impregnating resin (36) comprises at least one filler in the form of inorganic particles of size preferably less than 150 μιη such as for example: silica (SiO 2), alumina (Al 2 O 3), Magnesia (MgO).

Advantageously, the impregnating resin (36) is selected from higher thermal class resins (or equal) at 180 ° C, such as for example: Elmotherm VF970 ® resin, Aquanel VF 111 ®. Any combination of resin 35, 36 with or without a charge agent in the form of inorganic particles can be envisaged, and the person skilled in the art knows how to choose the most suitable combination for the intended application.

Advantageously, the characteristic parameters of the enameling varnish 35 are chosen from:

dynamic viscosity: 100 to 4000 mPa.s, and / or

- temperature class: 120 ° C to 240 ° C (120/140/155: 180/200/220/240 ° C), according to IEC 60085: 2007, and / or

- dielectric strength greater than or equal to 30 kV / mm, and / or

- More preferably the chemical nature is selected from: polyurethane (PUR), thermoplastic elastomer (TPE).

By way of example, the enameling resin (35) may be chosen from the VOLTATEX WIRE® range (Dupont).

The enameling resin (varnish) can be crosslinked by the action of heat or by the action of ultraviolet rays. For the latter, for example, the resins of Green Isolight International:

- the GII 206 which has a class of 280 ° C and which is based on polyester acrylate;

the GII 200 which has a class of 120 ° C and which is poly-alcohol modified acrylate.

Advantageously, the characteristic parameters of the impregnating resin 36 are chosen from:

dynamic viscosity: 100 to 1000 mPa.s, and / or

- dielectric strength greater than or equal to 30 kV / mm

- Thixotropic ability,

- More preferably the chemical nature is selected from: epoxy, polyester, polyester-imide. By way of example, the impregnating resin 36 may be chosen from the ranges: VOLTATEX® (Dupont), DAMISOL® (VonRoll).

A device 1 as described above is manufactured by means of the method according to the invention, which implements at least one positioning device 40 of said conductors 2, said positioning device 40 preferably including among other things a positioning frame 50.

During manufacture, the conductor preparation step 2 comprises at least one saving step 60 in any area of the conductors 2 which must remain free of any insulation.

In advanced embodiments, the positioning device 40 further comprises a mechanical clamping means 70 of the conductor, preferably associated with the frame 50. Advantageously, the step of disposing said prepared flat conductors (2) in said positioning device 40 comprises a positioning step of at least one spacer 32, said spacer 32 connecting at least two flat conductors 2 between them.

Most preferably, the device 1 comprises at least one porous spacer 34. Such a characteristic makes it possible to ensure:

a good impregnation of the resin 31 by capillarity, in the variants of the process where the assembly of the device 1 is carried out by impregnation of resin 31,

- A security of absence of electrical contact between two consecutive conductors 2 by establishing a spacing distance corresponding to the thickness of the spacer 32.

a retention effect of the resin 31 in the case where the inter-conductor gap 2 is substantial. Preferably, it is considered that there is a substantial spacing between the conductors 2 when the difference is between 1 and 5 mm. Preferably, in order to ensure optimum maintenance (during manufacture) of the constituent elements of the device 1 such as the conductors 2 and the spacers 32, said frame 50 comprises at least one protrusion 75 at the end of which is positioned a stop (eg mechanical stop) 76.

Advantageously, said stop 76 acts as a geometric reference area in the space for among other things at least one of: flat conductor (s) 2, spacer 32.

Advantageously, said growths 75 are in sufficient number to ensure:

A geometrical positioning of each flat conductor 2, and / or spacer 32 in the dedicated variants, with respect to said frame 50, and / or,

A maintenance without displacement of the conductors 2, and / or of the spacer (s) 32 in the dedicated variants:

o between them (driver 2 / driver 2, and / or driver 2 / spacer

32, and / or spacer 33 / spacer 34, and / or

o with said frame 50.

After extraction of the connector, and removal of the mist 76, the resin flue so that it covers the bearing zone of the stop 76. The stop 76 can also rely on a saving

Regarding the mechanical clamping, it may for example consist of a screw head 77 and a bearing washer 78 passing through the slots in the conductor 2, all screwed onto a rod 79 geometrically secured to the frame 50.

Advantageously, according to an advanced variant of the positioning device according to the invention, the latter is also able to generate spatial constraints at the internal dimensions of said connector device 1, by bringing the flat conductors 2 together. This approximation is preferably effected by the use of an actuatable positioning device 40. Preferably, said positioning device is able to adopt several positions, that is to say that said positioning device is able to hold the flat conductors of the busbar in at least one manufacturing position with a preferential orientation:

• one or more positions (s) Εχ (including an initial position),

• a tight position S (corresponding to the final position)

The "spaced" position E _x corresponds to a provision in which the different conductors are further apart from each other during manufacture (compared to their desired position in the finished product). The position for which the spacing is the largest between the conductors, advantageously corresponds to the initial position I of manufacture.

The "tight" position S corresponds to the desired layout of the drivers in the finished product.

In the case where the positioning device is not mobile, the (or) position spaced apart and the tight position are combined (in particular the initial position and the end position are identical).

Thus, advantageously according to the method, the positioning device 40 can be mobilized between: at least one manufacturing position called "spaced position" Εχ, and a manufacturing position called "tight position" S. On the other hand, the process is remarkable in that it comprises at least one displacement step D consisting of passing said positioning device from said spaced apart position to said tight position.

Thus, in preferred embodiments of the positioning device 40, the latter comprises among others at least one mobilization means 80, enabling the actuation of said positioning device 40, such as for example: a motor, a mechanical joint, a jack pneumatic. When the method implements an actuatable positioning device 40, the method may comprise at least one tightening step R corresponding to the passage of a spaced position E _x (several spaced apart positions may be provided) to the tight position S.

Preferably, according to the method, a single tight position is provided, corresponding to the final position of the elements of the device 1.

The skilled person knows how to choose the number and the order of arrangement of the tightening steps, with each other and vis-à-vis the other manufacturing steps, depending on the characteristics of the device 1 to be manufactured and the application referred.

Also, the method advantageously further comprises a step consisting in arranging at least the flat conductors 2 (optionally prepared) in a tank 90, as shown in FIG. 3, able to receive at least one impregnating resin 36 (placing step in the tank, distinct from the positioning step in the positioning device). Moreover, the step of assembling said device

1 further comprises an impregnation step of impregnating at least said flat conductors 2 with at least one impregnating resin 36. The method also advantageously comprises an extraction step X of the device 1 of said tank 90. Said resin of impregnation 36 has physicochemical characteristics allowing its maintenance in the form of a coating layer on all accessible faces of said flat conductors

2 after extraction (extraction step X) of the latter from said tank 90 (preferably after extraction of all the constituent elements of the device and / or manufacturing means such as inter alia: the positioning device 40).

Advantageously, in advanced variants of the process, the extraction step X follows a draining step V of the tank 90, said emptying is preferably carried out to a drain buffer tank (possibly identical the resin reserve buffer tank 91 bringing the resin to the impregnating tank 90, which facilitates for example the recycling of the material).

Preferably, the device 1 is assembled by resin impregnation 36, said impregnating resin 36 is introduced into the tank 90 (for example by the bottom (bottom) or laterally to the device 1, for example from a buffer storage tank of resin 91), as presented successively in FIGS. 3 to 5, in which the level of impregnating resin 36 is seen to rise progressively in the tank 90 so that the impregnation does not take place by sprinkling (covering of the device 1 " from top to bottom ") but by raising the impregnating resin 36, ie by rising between the constituent elements of the device 1 (conductor 2, spacers 32, etc. ..) and / or between the means of manufacturing implemented in the process, such as inter alia: positioning device 40, clamping means 70, etc.

More preferably, the impregnation is carried out by being brought into contact, at least in part, with said flat conductors 2. Even more preferably, by rising around said flat conductors 2 (complete coating, for example when there is no 'savings).

Advantageously, the speed of the impregnation is controlled by the regulation of the internal pressure in the tank 90.

Preferably, the tank 90 is a closed vessel (directly closed or able to be closed).

According to variants of the process, the rise of the impregnating resin 36 is carried out at ambient pressure, by capillarity. In these variants, the tank 90 can be closed or not.

Other variants of the process use a closed tank 90. In this case, sub-variants are provided, depending on the chosen combination of steps detailed below. Thus, in addition to the vat operations of the connector device 1 and its removal, opening and closing of the tank 90, the closed tank 90 method comprises among others at least one of the following steps:

Step of placing the vessel 90 under depression, preferably at a value of less than or equal to 1 bar: this depression serves inter alia to introduce the resin by pressure difference from a buffer tank,

A step of partial evacuation (carried out at least once during the manufacturing process), preferably leading to the tank 90 at a pressure of between 0.1 and 0.3 bar and / or preferably taking place during a time between 1 and 3 minutes. This step makes it possible to extract the air bubbles trapped in the connector device 1,

• A step of pressurizing said tank 90 (carried out at least once during the manufacturing process), preferably bringing the tank 90 to a pressure of between 2 and 3 bars and / or preferably taking place during a lapse of time. time between 2 to 5 minutes (this excess pressure is practiced obviously, possibly after the depression stage, and in all cases after the introduction of the resin 36 in the tank 90, it allows to route the resin in all the cavities of the device 1).

The skilled person knows how to choose the order, the presence or the absence, the nature and number of repetitions most suitable for the steps of setting depression and regulating the internal pressure of the tank 90, partial vacuuming , pressurized, entering the manufacturing process of the device 1.

Advantageously, in certain advanced variants of the method implementing a tank 90 (open or closed), where the positioning device (40) is operable, the method is remarkable in that: The positioning device 40 is placed in the tank 90 (bottling stage) in a spaced position E _x , as shown in FIGS. 3 and 4, and

The displacement step D, consisting in tightening the positioning device 40 to bring the conductors 2 closer to each other until the final tight position S that can be seen in FIG. 5, is performed once the impregnating resin 36 completely impregnated the device 1 (the level of resin 36 in the tank 90 makes it possible to completely cover the device 1), before the emptying step V if it exists or otherwise before the extraction step X.

Advantageously, in certain advanced variants of the method implementing a tank 90 (open or closed), where the device 1 is assembled by resin impregnation 36, the manufacturing method further comprises a crosslinking step F of the (or) impregnation resin 36, carried out after the extraction step X. The crosslinking of the impregnating resin 36 can be carried out for example: spontaneously at room temperature, or in an oven, or under the action of UV radiation.

Advantageously, in certain advanced variants of the method implementing a tank 90 (open or closed), the step of bottling at least one of among others: positioning device 40, flat conductors 2, spacer (s) 32, consists in placing in said tank 90 said elements so that all of the conductors are inclined, that is to say that the normal to the plane corresponding to the largest surface of the flat conductors 2 is inclined relative to vertically at a typical angle between 45 ° and 85 °.

Or, advantageously, in other advanced variants of the method implementing a tank 90 (open or closed), the step of bottling at least one among other things: positioning device 40, flat conductors 2, spacer 32, consists in placing in said tank 90 said elements in a preferred orientation so that the normal to the plane corresponding to the largest area (in terms of product finished) of the device (busbar) is inclined to the vertical by a typical angle between 45 ° and 85 °. This inclination makes it possible to limit the entrapment of air bubbles under a flat horizontal surface and / or in the recesses during the rise of the impregnating resin.

Advantageously, the conductors 2 are positioned in a spaced apart position (E _x ) such that the difference is greater than the thickness of the desired resin, so that the conductors 2 are brought closer to the emptying step if this exists or else before the step of extraction of the tank 90. The approximation of the conductors 2 allows among other things to chase any air bubbles. The use of a spaced apart position E _x during the impregnation avoids the eventual entrapment of air bubbles between the conductors 2 once they are in the tight position S.

Advantageously, the method according to the invention is remarkable in that in advanced variants of the step of preparing the flat conductors 2, it further comprises at least one iteration of the following cycle of steps:

First of all, to deposit a layer of enameling varnish 35 of thickness A, preferentially by dipping followed by dripping (nevertheless, any other suitable method - depending on the chosen resin - can be implemented, such that spray or aerosol coating or by centrifugal coating),

• then crosslink the enameling varnish 35.

The skilled person knows how to choose the iteration number of the step cycle presented before, so as to obtain a final desired thickness B of enameling resin 35, coating said flat conductors 2 (the coating can be carried out for each driver individually, or for all drivers in one past). Among other things, the number of iterations (and thus the final thickness B) is chosen according to the voltage that the device must support.

Preferably, said thickness B is between 30 and 200 microns, to allow the device to operate at a voltage between 300 and 1250 volts. Preferably, said thickness A is between 3 and 15 microns. A first interest of these various steps A resin deposition (varnish) enamelling 35 is to avoid the creation of micro-cavities in the thickness of the insulation (any micro-cavity being likely to become the seat of landfills partial damage to the durability of electrical performance of the insulation and / or insulation).

A second interest is to reduce the risk of a local accidental lack of varnish because the layers are deposited independently of each other.

A third advantage will be to take advantage of characteristics specific to each type of varnish, for example a first layer with a high adhesion ability on the conductive surfaces, a subsequent layer (different resin) with higher mechanical performance.

The crosslinking of the enameling varnish 35 may for example be carried out spontaneously at room temperature or in an oven, or under the action of UV radiation.

Advantageously, the method according to the invention is remarkable in that in advanced variants of the step of preparing the flat conductors 2, it further comprises at least one step of preparation (treatment) of the surfaces, chosen for example between others among: degreasing, dedusting.

Examples of preferred embodiments Hereinafter are briefly presented two particularly preferred embodiments of the invention. The general description will be usefully referred to for the details of the steps mentioned. However, the realization of any variant provided according to the general description presented above is of course conceivable.

1) busbar made with "raw" conductors assembled by impregnation in the tank

The method of manufacturing such a busbar comprises in particular the following steps:

Arranging the prepared conductors 2 (for example: degreased) in the positioning device 40, in an initial position separated (position I and identical position Ex),

Arranging the assembly constituted by the positioning device 40 and the conductors 2 in the tank 90 so that the normal to the plane corresponding to the largest surface of the device 1 (as a finished product) is inclined relative to to the vertical axis at an angle between 45 ° and 85 °,

• perform a step of depression of the tank 90,

• assemble the constituent elements of the device 1 by:

impregnation of resin 36, by going back up between the constituent elements of the device 1 and the manufacturing means, and o realizing a displacement step D consisting in tightening the positioning device 40 to bring the conductors 2 closer to one another until at the final tight position S, and o carrying out a partial evacuation step of the tank 90, and o performing a step of pressurizing the tank 90,

Carrying out a step of emptying the tank 90,

Carrying out a step of extracting the device 1 from the tank 90, Carrying out a step of crosslinking the impregnating resin 36,

• collect the device 1 as a finished product.

2) busbar made using enameled conductors assembled by impregnation in tank

Preparing the flat conductors 2 by deposition of enameling varnish 35 (followed by a step of crosslinking said varnish 35, and possibly reiteration to obtain several layers of the varnish 35),

Arranging the prepared conductors 2 in the positioning device 40,

• perform a step of depression of the tank 90,

• assemble the constituent elements of the device 1 by:

impregnation of resin 36 by raising between the constituent elements of the device 1 and the manufacturing means, and

o performing a partial evacuation step of the tank 90, and o performing a step of pressurizing the tank 90,

Carrying out a step of emptying the tank 90,

Carrying out a step of extracting the device 1 from the tank 90,

Carrying out a step of crosslinking the impregnating resin 36,

• collect the device 1 as a finished product.

Interest of industrial implementation The set of technical characteristics previously set forth clearly demonstrate the utility and the potential for industrial application of the device and the manufacturing method proposed.

The applicant thus recalls, inter alia, that:

• the removal of polymer films and / or adhesives (glue), which have limited temperature characteristics, makes it possible to move to a much higher thermal class:

o At least, the thermal class of the most common resins is 180 ° C whereas the current rolled busbars are designed to work at a temperature below 130 ° C,

o the use of the device according to the invention at an even higher temperature up to 240 ° C is achievable by the use of more sophisticated resins, available on the market and which meet the desired standards.

• The use of higher performance films (PEN, PEEK, POLY-EVlDE type) is no longer a relevant approach, as these are very expensive compared to a resin of the same temperature class, moreover, if the availability of such films does not cause any concern, the existence of high-temperature glues suitable for the film of rolled "busbars" is not yet an obvious industrial reality.

The expected economic gain for a multilayer connector according to the invention can reach 10 to 50% given the high cost of high temperature films

• The manufacturing process lends itself to mass production of "busbars", by the use of large capacity tanks in which several different "busbars" conformations and a large number of "busbars" can be processed simultaneously. Thus, the Depositor considers that the production capacity of "busbars" is likely to be multiplied by at least a factor of 5, by the use of the proposed process, for a similar amount of industrial investment.

The manufacturing process is also suitable for serial production of busbars from conductors with complex geometries (multiple folds, non-planar shapes, etc.).

the resin impregnation manufacturing process allows the realization of significant energy savings by eliminating the use of heat presses (with an estimated ratio of at least 3 in favor of the proposed process).

The proposed method has the possibility of using varnishes loaded with inorganic particles, which degrade less under partial discharge constraints. This technical possibility makes it possible to obtain a controlled lifetime in the presence of partial discharges, contrary to the current technology which requires the absence of partial discharges.

The proposed method makes it easier to envisage a global ecological approach, by offering the possibility of using aqueous solvents in places and place organic solvents in the resins.

Claims

A method of manufacturing a multi-layer connector device (1) capable of making an inter or intra connection static converter (s) of electrical energy, said device (1) comprising at least two flat conductors (2) and at least one insulating material (30, 31, 32, 33, 34, 35, 36) disposed between said two conductors (2), said method being characterized in that:

The flat conductors (2), possibly prepared (2), are positioned in a tank (90) in a geometric position such that the conductors (2) are kept parallel and spaced apart by a value at least equal to the thickness of the the desired electrical insulation, said conductors (2) having a preferred orientation,

These said prepared flat conductors (2) are impregnated with at least one impregnating resin (36) introduced into the tank (90), the said impregnating resin (36) having physicochemical characteristics which, after extraction from the tank, are maintaining in the form of a coating layer on all of the accessible faces of said flat conductors (2),

The device (1) is extracted from said vessel (90),

The cross-linking of said impregnating resin (36) is carried out to assemble the flat conductors.

2. A method of manufacturing a connector device (1) according to claim 1, characterized in that places the conductors (2) in a positioning device (40) does not generate spatial constraints in terms of external dimensions said device (1) before introduction of the impregnating resin (36).

3. A method of manufacturing a connector device (1) according to claim 1 or 2, characterized in that one poses savings (60) to preserve conductive surfaces of the flat conductors (2) of a recovery by the resin and / or spacers (32) are placed to keep apart the flat conductors (2).

4. A method of manufacturing a connector device (1) according to any one of claims 1 to 3, characterized in that the impregnation is carried out by raising the impregnating resin (36) between the constituent elements. of the device (1).

5. A method of manufacturing a connector device (1) according to one of claims 1 to 4, characterized in that a closed vessel (90) is used and the method comprises at least one of: a step of in depression of the tank (90), a step of partially evacuating the tank (90), a step of pressurizing the tank (90) each step being performed at least once.

6. A method of manufacturing a connector device (1) according to any one of the preceding claims, characterized in that the emptying of the tank (90) before extracting the connector device (1).

7. A method of manufacturing a connector device (1) according to one of claims 1 to 6, characterized in that positions the conductors (2) in a spaced position (Εχ) such that the difference is greater than 1 impregnation resin thickness (36) desired to then bring the conductors (2) before the emptying step if it exists or otherwise before the step of extraction of the tank (90).

8. A method of manufacturing a connector device (1) according to one of claims 1 to 7, characterized in that said flat conductors (2) are arranged in an inclined manner in the tank (90), the normal to the corresponding plane to the larger surface of the device (1), as a finished product, being inclined with respect to the vertical by an angle of between 45 ° and 85 °.

9. A method of manufacturing a connector device (1) according to one of claims 1 to 8, characterized in that to prepare the flat conductors (2) is deposited at least one layer of enameling resin (35) d A thickness on said conductors (2), to then crosslink said enameling resin (35).

10. A method of manufacturing a connector device (1) according to one of claims 1 to 9, characterized in that prepares the flat conductors (2) by at least one surface treatment step.

11. Connector device (1) obtained via the manufacturing method according to one of claims 1 to 10, characterized in that it comprises at least two flat conductors (2) and at least one insulating material (30) also having function assembly.

12. Connector device (1) according to the preceding claim, characterized in that at least one resin (31, 35, 36) comprises at least one filler in the form of inorganic particles.

13. Means for implementing the method according to any one of claims 1 to 10, characterized in that the means comprise a tank (90) and a geometric positioning device (40) of the flat conductors (2) such that the conductors are kept parallel and separated by a value at least equal to the thickness of the desired insulation, which positioning device (40) does not generate spatial constraints at the external dimensions of said connector device (1) and the conductors 2 are positioned so that the normal to the plane corresponding to the largest surface of the device 1 (as a finished product), is inclined with respect to the vertical axis of a angle between 45 ° and 85 °.

14. Use of the connector device (1) according to any one of claims 11 to 12 as inter or intra converter connector (s) static (s) of electrical energy.